Powerful technology, flexible to use36D twin-screw extruders – pipe extrusion series

Engineering Value

*Image source: www.unicor.com

2 36D pipe extrusion series Facts and figures

PVC foam core pipes

PVC corrugated pipes*

Highly filled PVC pipes PVC pressure pipes

Various PVC pipes for pressure and non-pressure applications

Applications

Other applications

– Mining pipes (M-PVC)– Well pipes (U-PVC)

Technical data and dimensions

KMD KMD KMD KMD KMD 75-36 E2/R 90-36 E2/R 108-36 E2/R 114-36 E2/R 133-36 E2/R

Output range [kg/h] 210-540 300-770 450-1000 480-1200 600-1550

Motor power output [kW] 56 76 113 118 165

Screw length [L/D] 36 36 36 36 36

Screw diameter [mm] 75 90 108 114 133

Screw heating/cooling Internal Internal Internal Internal Internal

Extrusion height [mm] 1000 1150 1150 1150 1150

Dimensions [mm]

Length incl. adapter 4600 5420 6350 6680 8030

Width incl. control cabinet 1300 1400 1400 1420 1700

Height incl. hopper 2420 2520 2540 2580 2660

Facts and figures regarding the 36D twin-screw extruder pipe extrusion series

Combine powerful technology and a high level of flexibility –with the 36D twin-screw extruders

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The parallel 36D twin-screw extruders have been engineered specifically for PVC processing. Their objective: Outstanding cost-efficiency thanks to a high output rate and excellent product quality. With a wide product portfolio that is based on our modular machine concept, we can offer applica-tion-specific production solutions which are high-performance and extremely cost-effective.

Your advantages at a glance:– Low maintenance costs thanks to internally

heat-balanced screws and air-cooled barrels– Safe degassing even with highly filled

mixtures– Wider processing range of different formula-

tions and materials thanks to high process flexibility

– Increased cost-efficiency thanks to a longer service life of the processing unit

– High output rate with perfect product quality– Excellent price-performance ratio

Impressive encounter Take a tour of the 36D twin-screw extruder for pipe extrusion

Standard dosing unitfor processing many different materials

Robust gearboxensures low mainte-nance costs and a long service life

Drive motoreither AC or DC technology

Gearbox lubrication unitfor filtering and adjusting the temperature of the gearbox oil

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Vacuum degassing unitwith double solids separator

36D processing unit with molybdenum-welded screws and deep-nitrided, air-cooled barrel

Rectangular filling openingallows optimum screw filling

Vacuum degassingwith a stable waste pipe and a quick connection for easy cleaning

6 36D pipe extrusion Screw concept

High process flexibility thanks to the optimized screw concept

Due to their screw concept, the 36D twin-screw extruders are ideally suited for producing U-PVC, M-PVC and foam core PVC pipes as well as PVC-O pipes.

High Performance Geometry (HPG)The HPG screw concept achieves high process flexibility thanks to the long effective pre-heating length. This results in significant benefits for the processors.

11D 25D

Doppeldrossel

Your benefits: – Wider processing window when

processing different formulations and materials

– Optimal incorporation of color, blowing agent, chalk and regrind

– Low compression values in the area of the throttle zones

– Excellent melt homogeneity thanks to optimal material processing

– High process flexibility in production– Ideally suited for processing highly

filled PVC compounds

Double throttle: The longer pre-heating length of the HPG screws results in low compression values and therefore a prolonged service life. A further advantage is the outstanding material degassing.

36D single degassing extruder for pipes (current series)HPG single degassing geometry

Double throttle

Optimal wear-resistance thanks to the molybdenum welded layer

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As standard wear pro-tection, KraussMaffei Berstorff offers patented molybdenum welded screws.

All twin-screw extruders are equipped with deep-nitrided barrels. A nitriding steel is used as the construction material as it enables a particularly high surface hardness to be achieved in the barrel bores. The molybdenum wear-resistant layer on the screw flights and the deep-nitrided barrel bore surface are an ideal friction combination with excel-lent sliding properties and minimal wear.

For particularly abrasive filler materials and mixtures that contain a high propor-tion of filler, KraussMaffei Berstorff offers tungsten carbide welded screws in com-bination with bimetallic barrels.

Finely dispersed, isotropic join of a molybdenum hardfacing

Homogeneous, isotropic carbide distribution of a tungsten-carbide hardfacing

88 36D pipe extrusionModular design

The recipe for success with cost-effective, customer-specific solutions – Our modular extruder concept

The extruder conceptStarting with a universal base frame and a standard barrel, KraussMaffei Berstorff can supply customized extruders that are closely matched to customer requirements. The screws are internally heat-balanced as standard. The internal screw heating/cooling contributes significantly to energy savings and an optimum melt homoge-neity. The system is self-regulating and completely maintenance-free. A regulated metering unit with metering spirals enables a constant specific melt throughput, even when using different formulations.

Optionally, the material of the main com-ponent can also be fed gravimetrically, and several secondary components can be

Like all the extruders built by KraussMaffei Berstorff, the twin-screw extruders in the 36D series are engi-neered to an intelligent modular design.

metered gravimetrically or volumetrically. Gravimetric material weighing ensures high process consistency and offers potential material savings at the same time.

Air-cooled barrelsThe air cooling unit is part of our stan-dard system. The system uses aluminum half shells with cast-in heating coils and integrated cooling fins. The temperature sensors are each fitted to the sides of the barrel between two cooling blocks in order to keep control circuits as short as possible. The system is completely maintenance-free. With this system, there is no risk of scaling, which can occur with copper fins, for example. This ensures that a constant high heat transfer is always guaranteed.

Aluminum cooling blocks with cast-in heating coils Cooling fan

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Reducing material costsHighly filled pipes of up to 60 phr chalk in the main component

Higher filler content significantly reduces costs during the pro-duction of compact PVC pipes – however, this should not be at the expense of product quality.

Special metering unit for highly filled materialIn the highly competitive PVC pipe market, in which the producers are now subjected to constantly increasing price pressures, the trend is moving towards use of the highest possible percentage of fillers, particularly for drainpipes. In par-allel with this, however, higher outputs are also required while maintaining per-fect product quality. Formulations with a high proportion of chalk (up to 60 phr in the main component) require a significantly higher energy input, which is optimally achieved by the larger effective preheat-ing length. The twin-screw extruder of the 36D series excellently masters this processing challenge. The extruder has a horizontal-vertical metering unit in order to process formulations with a high proportion of chalk (more than 30 phr). There is also the option to integrate a regenerative metering unit, as the illus-tration shows. The 36D concept guaran-tees absolutely safe material degassing for normally filled as well as for highly filled PVC compounds.

KMD 90-36 E/R equipped to process highly filled PVC compounds

Horizontal metering unit with co-rotating twin metering screw for highly filled dryblend (30-60 phr CaCO3)

Gravimetric metering for regrindVertical metering unit

Color metering

10 36D pipe extrusionDirect extrusion

Reduce material costs and increase flexibilityHighly filled pipes of up to 100 phr chalk using direct extrusion

The KraussMaffei Berstorff con-cept for high filler content reduces material costs enormously.

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The innovative machine concept can be equipped with multi-component gravi-metrics with up to six components, three of which can be added gravimetrically or volumetrically. This offers enormous material cost savings, as it enables maximum metering of cost-cutting material mixtures. This means that, with gravimetric weighing and highly filled dryblends (up to 60 phr chalk in the main component), regrinds and regranulates (up to 20 phr) and even pure chalk can be added. Thanks to the direct extru-sion of chalk, the total chalk content in the mixture can be increased to 100 phr. Using secondary component metering, processing aids, color and blowing agent can be added.

Multi-component metering systemfor direct extrusion

The benefits of direct extrusion: – Energy savings– Increased mixing capacity– No material segregation during

transport– Optimal product quality thanks to good

dispersion of the filler materials

12 36D pipe extrusionFoam core pipes

PVC foam core pipe production with twin-screw extruders from the 36D series

Reduce material costs by up to a third by using foam core pipes.

Material costs when producing PVC foam core pipes can be significantly reduced by using 36D twin-screw extruders com-bined with the PVC three-layer pipeheads developed by KraussMaffei Berstorff. In doing so, the 36D twin-screw extruder guarantees peak product quality. The extruders can be used as main extrud-ers as well as coextruders. The foaming decreases the density of the pipe-core layer by up to 0.6 kilograms per cubic decimeter.

The density of the entire pipe can there-fore be reduced by up to 30 percent in comparison to compact PVC pipes. PVC foam core pipes are being used more and more for non-pressure applications, such as drainpipes.

Extruder combination for the production of PVC foam core pipe consisting of: A KMD 75-36 E/R for the outer and inner layers and a KMD 90-36 E/R to produce the foam layer

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C6 control system – flexible system for open-and closed-loop control and monitoring of an extrusion line

Various operating configurations are available

in terms of both its operation and its functionality, which have proven successful over a great many years.

Maximum flexibilityThe C6 control system offers the user an incredibly high level of flexibility. The composition of parameter pages can be chosen freely, and display and para-meter texts can be tailored to individual requirements. In addition, the system components can be connected and dis-connected as required.

Fast, secure access management using RFID technologyThe C6 control system allows fast, secure access by means of non-contact iden-tification using RFID readers. Remote diagnostics via the Internet and data interfaces to connect to the company network tip the balance to make the C6 control system the perfect solution for all your extrusion line’s control tasks.

With its numerous monitoring and control functions, the C6 control system ensures optimal production preparation and transparency throughout the production process, thereby satisfying the most stringent requirements for excellent product quality and a high level of process reliability.

Multi-touch technology for intuitive operationThe C6 control system is equipped with the latest multi-touch technology and state-of the-art hardware components. A high-resolution 24-inch full HD screen provides an optimal overview. The intui-tive operation and clear screen layout facilitate fast intervention and provide a comprehensive process overview. Units and functions can easily be operated and activated via the touchscreen display. With the C6 control system, KraussMaffei Berstorff has placed a particular empha-sis on maintaining continuity in the design

With its new, innovative C6 control system, KraussMaffei Berstorff offers fast, direct access at all times to the individual units of an extrusion line, the extruders which work conjointly to produce the product, and to integrated downstream equipment.

Your benefits: – Modern, innovative operating philosophy– Fast, intuitive operation– Highly flexible – Maximum process reliability– Optimal monitoring of integrated

system concepts and standalone machines

– A variety of user-friendly models

Swivel-mounted on switching cabinet (standard version)

Mounted on switching cabinet door, tilting (option)

Mobile version (option)Boom-mounted version (option)

14 36D pipe extrusionFurther information on OEE Plus

OEE PlusBoosting cost-efficiency for you

For more information about OEE Plus, visit: www.kraussmaffeiberstorff.com/oeeplus

Availability Performance Quality

High overall equipment efficiency (OEE) is a fundamental prerequisite for your company’s success. KraussMaffei Berstorff’s product portfolio comprises tailored machines and lines along with perfectly matched services that increase the economic efficiency and the sustainability of your production. Benefit from our proven know-how of extrusion technology in any application.

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KraussMaffei BerstorffA strong brand in a unique global group

KraussMaffei GroupComprehensive expertise

Value-proven Extrusion Technology solutionsAround the world, KraussMaffei Berstorff stands for reliable and value-proven solutions in Extrusion Technology. These range from using individual extruders for degassing in polymerization, com-pounding, pipe, profile, film and sheet extrusion, physical foaming and the manufacture of technical rubber articles and intermediates for tire production up to complete extrusion lines. All machines and systems from KraussMaffei Berstorff are custom-configured, for example for the chemical, automotive, construction, packaging or pharmaceutical industry.

Unique selling proposition Technology3

The KraussMaffei Group is the only pro-vider in the world to possess the essen-tial machine technologies for plastics and rubber processing with its KraussMaffei, KraussMaffei Berstorff and Netstal brands: Injection Molding Machinery, Automation, Reaction Process Machinery and Extrusion Technology.

The group is represented internationally with more than 30 subsidiaries and over ten production plants as well as about 570 commercial and service partners. This is what makes us your highly skilled and integrated partner. Use our com-prehensive and unique expertise in the industry.

You can find additional information at: www.kraussmaffeigroup.com

There for you around the worldKraussMaffei Berstorff is your partner – from the first planning meeting through development of the best possible techni-cal and business solution up through commissioning, servicing and production of your system. We guarantee high-quality advice, solution expertise, reliable spare parts logistics and fast-reacting service during each phase. Our goal is increasing your success.

Individualized serviceBenefit from KraussMaffei Berstorff’s reliable service. Our customer service team and experienced fitters, technicians and engineers are there for you as quickly as possible and even help on location to optimize your systems and processes and to minimize downtime as much as pos-sible. Rely on our highly skilled repair and spare parts service

You can find additional information about KraussMaffei Berstorff at: www.kraussmaffeiberstorff.com

The KraussMaffei Group has a global presence. Countries with subsidiaries are marked in light blue. In the white-colored regions, the Group is represented by over 570 sales and service partners.

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Our 36D twin-screw extruders have been engineered specifically for outstanding cost-efficiency for processing PVC. With a wide product portfolio, based on our modular machine concept, we can offer application-specific production solutions which are high-performance and extremely cost-effective.

The decisive benefits for you include the specially engi-neered screw concept for very gentle, homogeneous material processing. Long process units increase process reliability and offer high production reliability in a broad range of applications. You benefit from high output, constant product quality over the whole output range and an outstanding price-performance ratio.

Powerful technology, flexible to useThe 36D twin-screw extruder pipe extrusion series